Knitted fabric-elastomer composite preferable for transfer or film-coating

Abstract

The present invention relates to a process for producing a knitted textile material that, when transfer or film-coated, is suitable for use as an artificial leather substrate. The inventive procedure involves (a) producing an elastomer composition of at least four ingredients (an anionically-stabilized waterborne polymer dispersion, an acid-generating chemical, a cloud-point surfactant, and a foam-stabilizing surfactant); (b) incorporating sufficient gas into the liquid mixture to generate a spreadable foam; (c) applying the foam onto a porous knitted textile substrate; (d) heating said foamed fabric until the elastomer coagulates over the fabric substrate; and (e) drying the resultant composite without destroying the coagulated structure. The resultant composite obtains a pliability, compressibility, and drape that is similar to that of leather and a surface that is suitable for transfer or film-coating to produce artificial leather. The composite may be utilized as upholstery fabric in furniture or in automobiles, apparel, and the like.

What is claimed is:  
     
       1. A fabric-elastomer composite suitable for transfer-coating to produce a material having the appearance of leather, wherein said fabric-elastomer composite is comprised of a knitted textile fabric that has been coated with an elastomer composition comprising 
       (i) a waterborne, anionically-stabilized polymer latex;  
       (ii) an acid-generating chemical selected from the group consisting essentially of at least one organic ester;  
       (iii) at least one cloud-point surfactant;  
       (iv) at least one foam-stabilizing surfactant; and  
       (v) sufficient gas to produce a foam when introduced into said elastomer composition.